Wall panel systems and methods of assembling and refinishing wall panel systems

ABSTRACT

A wall panel system includes a plurality of extruded composite building panels for mounting to a wall that can be repaired or refinished. The panels include a plurality of ribs for contacting the wall and a lip for overlapping one of the plurality of panels immediately below. The wall panel system includes joint clips and flashings that over lap seams between abutting panels.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to and the benefit of U.S.Provisional Patent Application No. 62/164,993, filed on May 21, 2015,which is hereby incorporated herein by reference.

FIELD

The present disclosure relates to wall panel systems, componentsthereof, and methods of assembling and refinishing wall panels systems,specifically extruded composite building panels for siding panelsystems.

BACKGROUND

The following patents are incorporated herein by reference in theirentirety:

U.S. Pat. No. 6,758,996 discloses a granulated papermaking sludge thatis combined with a plastic to form composite materials that may beshaped into structural and non-structural articles.

U.S. Pat. No. 5,730,371 discloses a device and a process for delumpingpasty masses in waste materials from paper manufacture. The delumpingmeans employs at least one rotating cylindrical drum having a pluralityof flexible fingers mounted on the drum.

Wall panel systems, including siding panel systems and siding panels,for building structures may be formed of several different componentmaterials, including wood, plastic or vinyl materials such as polyvinylchloride (PVC), engineered wood composites, and fiber cement. It isdesirable to create a siding panel that provides improvedweatherability, durability, fade resistance, low maintenance, lowerenergy inputs, repairable and adaptability to various architectures.

A major trend in global building products is to create “resilient”building products that are designed to meet the conditions and realityof a post carbon, climate changing world. Various factors have becomeimportant to resilient products after devastating hurricane events suchas hurricanes Sandy and Katrina. Low carbon inputs and lower energyinputs are considerations of resilient products, but durability androbustness in design are also important. Materials use to construct theresilient products need to provide more protection against potentiallycatastrophic weather and the increasing number of severe or evendangerous weather events that climate change can produce. Protectionfrom hail impact, strong winds, and other general issues related tosiding are considerations for a resilient building product. In addition,resilient products strive for longer product life and stability over awide range of environmental conditions.

Thus, the resilient building movement refers, in part, to a material'sability to withstand the impact of nature including normal climaticconditions and natural disasters like hurricane, earthquakes, tornadoes,wildfires, winter storms, and flooding. More attention has been given tocreate building materials, products and practices that can withstandthese events with less damage, durability and longevity. As mentioned,resilient products also take into account energy inputs to the productand installation along with the ability to be serviced and maintainedwith local materials, parts, and labor. As a result, there is a need fora new generation of resilient and repairable building materials, andparticularly siding composites and wall materials that can withstandmore energetic weather conditions without failure or damage. Inaddition, there is a need for a siding product of high resilience anddurability that if damaged can be repaired easily by the owner.

The environmental benefits of productively utilizing paper-making sludgeand avoiding its disposal are considerable. Pulp and paper sludge (abyproduct of primary pulping operations, recycle streams or waste paperpulping and the like) represents an environmental and disposal problemfor manufacturers of pulp and paper. Generally, pulp and paper sludgeare unsuitable for paper making even though they contain the samecomponents—cellulose, lignin, hemicellulose, calcium carbonate, clay,and other inorganic components—as those present in the paper pulpitself. Calcium carbonate typically constitutes 20% and up to 75% of thesludge dry content, along with clay. These two minerals are typicallyloaded into paper as a coating and filler to improve the mechanicalcharacteristics as well as the appearance of paper. The resultingpaper-making sludge, particularly mixed office paper sludge, consistsprimarily of two major components, i.e., fiber and minerals finely mixedwith each other.

Paper sludge has traditionally been disposed of by landfilling,composting, incorporation into cement, and incineration. The latteroption, in turn, creates another problem, namely, disposal of theresulting ash, which often makes up to 50% or more of the volume of thesludge itself. The principal components of paper sludge ash are calciumcarbonate in the form of precipitated calcium carbonate (PCC) or groundcalcium carbonate (GCC).

A typical recycling mill processing 600 tons of wastepaper per day willyield 450 tons of pulp and produce 150 tons of paper-making sludge. The228 mills currently under operation in North America produce 9 milliontons of pulp residues, approximately 5 million tons of which iscellulose. The 154 European pulp and paper mills produce about 8 milliontons of pulp residues, approximately 4 million tons of which iscellulose. The conversion of such waste material into value-addedproducts has, therefore, long been desired.

Kadent GranTek, Inc. (Green Bay, Wis.) manufactures controlled sizedust-free granules, made of pulp and paper sludge, under the registeredtrademark BIODAC. The granules are a tight composite of organic andinorganic materials, i.e., cellulose fiber and minerals, and possess adeveloped porous structure. This granulated paper-making sludge isdescribed, for example, in U.S. Pat. No. 5,730,371, which isincorporated here by reference. The granules have a controlled size andpossess a developed porous structure; they are composed of organic andinorganic materials, i.e., cellulose fiber and minerals. It has beenfound that granulated pulp and paper sludge absorbs oil, lubricant orother hydrophobic fluids to a high extent.

It is also found that granulated pulp and paper sludge, compared withloose cellulose fiber, greatly improves the properties of fiber-plasticcomposites. Moreover, while reinforcement of polymer matrices byincorporation of cellulose fiber is well-known, the incorporation ofcellulose fiber into polymer hot melt is difficult to accomplish.Intensive prolonged mixing is ordinarily required to disperse the fiber.It is particularly difficult to obtain high-strength fiber-plasticcomposites, since fibers typically possess a high degree of fiber-fiberinteraction, tending to stick together in bundles of fibers andresisting dispersion of the individual fibers. It has been found,however, that granulation of pulp and paper sludge, approximately halfof which is typically cellulose fiber, reduces fiber-to-fiberinteraction prior to incorporation into the matrix, and improves themechanical properties of the composite.

As noted, oil, lubricant or other hydrophobic fluids may be incorporatedinto a paper sludge mix. One commonly used lubricant system is a blendof zinc stearate with an N,N′-ethylene bis-stearamide (EBS) wax. Otherlubricants include calcium stearate, magnesium stearate, non-metallicstearates; paraffin wax, polyester wax, polypropylene wax, fatty acidderived bis-amides, ethylene bis-oleamide, esters such as stearylstearate, distearyl phthalate, pentaerythritol adipate stearate,ethylene glycol distearate, pentaerythritol tetrastearate, glyceroltristearate, polyethylene glycol 400 monostearate, glycerol monooleate,glycerol distearate, and blended complex modified fatty acid esters.

Siding panels are one of the most visible and important parts of a homeas it provides functional protection as a sealing of the buildingenvelope and also provides aesthetic value to the home owner. Houses inAmerica often have their exterior walls clad with siding panels toprotect the predominately wooden construction from natural elements.

Current plastic or composite siding panels such as vinyl, cement fibercomposite and OSB (engineered wood) siding have various problems andissues related to weatherability, moisture absorption, impactresistance, robustness, and durability. In addition, these types ofsiding panel systems are not easily repairable if scratched, dented,cracked, marred or impacted and they show signs of defects that cannotbe repaired easily or at all. In most cases weather or human damagedsiding requires replacement. In many cases siding can also color fadedue to the coating or painting requirement of siding to protect thesiding from moisture.

Most current composite siding products require a coating comprised of ahigh performance paint, powder coating, or co-extruded cap stock toprotect the siding from direct moisture. Even using these methods, watervapor can still penetrate through or behind the composite siding whichcan cause damage that cannot be repaired or fixed thus requiringreplacement of the siding or siding piece.

Mechanical issues such as impacts, scratches, marring or othermechanical damage are also problematic for traditional composite siding.Replacement is often required. Current composite siding is notrepairable due to the material makeup, required coatings, and embossedsurface textures.

Vinyl siding has become popular over the last several decades because itis inexpensive, relatively easy to clean and relatively durable. Vinylsiding is usually produced by extruding a plastic polyvinyl chloride(PVC) or other plastic material with a colorant into a shape wherein aglossy or embossed surface is produced. These surfaces are typically ofa higher gloss, but will show most any type of impact, mar, scratch orheat distortion. Since vinyl siding is derived from thin PVC, it willfollow a wall very closely, but it also has many disadvantages includinglow impact resistance due to being thin and produced from a brittleplastic. Vinyl siding is also prone to heat distortion, melting,chipping marring, scratching, and provides limited protection of thehome building envelope. If vinyl siding is heated or burned, it givesoff a toxic and deadly gas substantially increasing the danger for thepeople within a home during a fire. Fire fighters are also subject tothese deadly fumes when fighting the many home fires in the UnitedStates annually. Furthermore, these gasses can even be released as aresult of exposure to the direct hot sun.

Another new problem for vinyl siding is melting due to indirect sunlightthat can be reflected from new low E energy efficient windows. Accordingto the National Association of Home Builders, double pane low-e windowreflection of the sun can focus sunlight almost like a magnifying glasson a vinyl siding. Vinyl has also come under attack given that PVCcommonly integrates various phthalate plasticizers which are knowncarcinogens and creates many other health concerns in its production,installation and end of life. There are no current means to repair vinylother than costly replacement.

Another example type of siding is orientated strand board (OSB) andmasonite siding, collectively referred to as “engineered wood” products.Engineered wood siding is well known to those skilled in the art whereinwood particles are compressed with various binders and additives into asheet which can then be made into various siding products. Engineeredwood siding products are made from various combinations of wood veneer,fibers or flakes, bound together with glues, resins, and/or waxes.Engineered wood composites for siding are typically produced usingcompression under heat and pressure which creates a smooth or embossedsurface that requires painting. For example, U.S. Pat. No. 5,908,496discloses lignocellulosic materials with a polyisocyanate binder tocreate siding. Plywood, oriented strand board (OSB) and hardboard arebasic engineered wood siding materials. Several different types andbrands of engineered wood siding have experienced moisture-relatedfailures and major lawsuits due to the product defects. Softwoodscommonly used in these products can have a significant moisture uptakeresulting in moisture swelling, mold, linear expansion, and rot issues.Although water proof resins or glues are used to hold the wood togetherand impart improved moisture resistance, these products still absorbwater or moisture from within the air that can create these problems. Inall cases, engineered wood products require some form of paint coatingto protect the primary engineered wood composite siding core. Even withpainting, paints can wear, scratch or degrade over time allowingmoisture transfer into the siding to create the potential for a myriadof problems for the homeowner. OSB siding can be prone to failures dueto mold, degradation, and other failures relating to moisture uptake.Similarly “Masonite”, a wood and resin mixture, has various problems andlawsuits for lack of performance, mold, moisture degradation and othermeans of failure. Some engineered wood composites require painting,coating and edge-sealing by their manufacturers. Even with paintprotection, material failures may persist.

Another example type of siding is fiber cement or fiberboard cementsiding/cladding that has recently developed into an alternative sidingsystem, especially as the acceptance of durable and renewable materialsincreases. Fiber cement is a product made generally of sand, cement andcellulose, and in most forms is a composite manufactured from slurriesof cement, sand, wood fibers, and water. The type of fibers, togetherwith their composition and orientation, are important as thesecharacteristics give the composite its mechanical properties. Kraft woodpulp is preferred as Kraft pulping largely removes alkaline-sensitivelignin, resulting in fiber compositions rich in cellulose (70-80%) andhemicellulose (20-30%). Manufactured products such as panels, planks, orshingles are formed by sequentially layering multiple thin films.Although manufacturing processes vary, these films representheterogeneous matrices having one side that is fiber rich and the otherthat is fiber poor. Bonding characteristics between laminates playimportant roles in the materials' durability and in-service performance.Formed sheets are either air-dried or autoclaved for the purpose ofcuring and moisture removal. The preferred method of autoclaving aids inthe reaction of sand with calcium hydroxide to form calcium silicahydrate. Improved hydration gives autoclaved fiber cement greaterstrength, but may also increase susceptibility to chemical attack,moisture movement and subsequent thermal-moisture stressing. Examples offiber cement products are disclosed in U.S. Patent Applications and U.S.patents related to fiber cement siding including U.S. Patent ApplicationNo. 2009/0019814, U.S. Patent Application No. 2009/0283201, and U.S.Pat. No. 6,418,610. As a siding material, fiber cement provides severaladvantageous properties such as rot resistance, termite resistance andbeing non-combustible. Because of these properties, fiber cement sidinghas become widely used in regions prone brush fires and elsewhere in theindustry.

Although there are other advantageous properties in fiber cement sidingrelative to real wood siding, problems with moisture absorption,mineral, and chemical leaching, lack of impact resistance, weight,brittleness and other problems exist with fiber cement siding inaddition to being one of the most expensive siding options. In additioncement fiber siding is very expensive and energy intensive in itsproduction. Many public reports discuss the degradation problems offiber cement siding over time. Fiber cement siding is often coated orpainted not only for color, but to reduce its high moisture absorbanceof the cement and cellulose fiber mixture. Fiber cement siding planksused in the siding are relatively heavy, brittle and require uniqueinstallation practices so that paint coatings are subjected toscratching, mar, cracking, breakage and other damage. These coatings orpaints typically cannot be repaired and therefore a portion or fullreplacement of the siding may be required. Recently a number of problemsand class action lawsuits have arose relating to decomposition and molddue to high moisture uptake and “leaching” of various minerals from thecement mixtures that have led to further mold problems and cracking ofcement fiber siding.

Fiber cement board is subject to many of the same processes as othercement-based materials. One of the more important processes iscarbonation, which results from the exposure of calcium-based phases ofthe cement component to CO₂ in air and water (Ca(OH)₂+CO₂→CaCO₃+H₂O).Carbonation of the matrix increases flexural strength through improvedbonding between the laminated films. As the product enters its secondyear of service, the degree of inter-laminar bonding may be countered bythermal and moisture stresses. Although carbonation initially aids ininter-laminar bonding, carbon reactions with hydration products may alsoserve to increase moisture movement, which compounds the effects ofthermal and moisture stresses. Weathering results in repeated cycles ofmoisture movement that ultimately serve to disrupt the cementitiousmatrix and reduce inter-laminar bonding. By moisture movement, we referto shrinkage and expansion due to the entry of water into and out of thepulp fiber. Through continued thermal and moisture cycling, thematrix-fiber interface becomes disrupted, ultimately reducing bondsbetween laminates and individual fibers. Further de-bonding results inpartial delamination; albeit scarcely perceptible to the naked eye.Also, at the molecular level, cellulose and hemicellulose are altered byatmospheric oxygen, alkali attack, and early biological degradation byfungi and other microorganisms. Much like incipient decay of wood, thisstage of degradation lacks softening, evident delamination, cracking orother signs commonly recognized as degradation. Physical and mechanicalproperties are nonetheless affected, and it is reasonable to assume aminimum 10% reduction in strength at five years. Various tests have beenperformed on cement fiberboard siding over a 10-30 year period andreports show at this stage, composite degradation is near complete andthe product is now at the end of its serviceable life. Disruptedmatrixes, cellulose depolymerization, and delamination are pervasive andstrength was reduced to half of as-manufactured conditions. Exposedsurfaces may show matrix sloughing, material loss, extreme delamination,cracking, and softening. Advanced degradation is usually accompanied byvisible fungal growth, which can be profuse—particularly on concealedsurfaces subject to poor drying. Being comprised largely of celluloseand hemicellulose, fiber cement may give rise to rich fungal assemblagesthat include common species of Aspergillums, Penicillium, Stachybotrys,Chaetomium, Aureobasidium, and Acremonium.

Yet another example type of siding is wood plastic composites (“WPC”)which can comprise various wood geometries mixed with a thermoplasticand various additives to create building products. Wood plasticcomposites refer to any composite that contains wood such as wood flouror wood fiber and plastic such as polyethylene, polypropylene, polyvinylor polyvinyl chloride. The WPC or “synthetic lumber” industry has growndramatically in the past ten years in North America. The mainapplications include decking, railing, boardwalk, porch, park benchseats and wood trim. The use of wood plastic composites in place oftraditional wood materials is driven by the characteristics of betterresistance to moisture and rot, better resistance to insects, lessroutine maintenance, and resistance to cracking, splitting, warping orsplintering. Synthetic lumber has been used as a substitute for wood inareas where wood can deteriorate quickly due to environmentalconditions. Although in the past, the commercialization of syntheticlumber was limited by costs, modern recycling techniques and low costextrusion manufacturing capability have permitted greater penetration bypolymer-fiber composite materials into the commercial and residentialmarkets. One such product manufactured under the trademark TREX, by TrexCompany, LLC, Winchester, Va., consists of a polyethylene-wood fiberblend which is extruded into board dimensions for decking applications.WPC used for window applications are smooth and also integrate a capstock coating for protection from UV light degradation and moistureabsorption. Example U.S. Patents related thermosetting molding compoundscontaining cellulose fiber as filler are disclosed in U.S. Pat. No.3,367,917, U.S. Pat. No. 3,407,154, U.S. Pat. No. 3,407,155, U.S. Pat.No. 4,282,119, U.S. Pat. No. 4,362,827, and U.S. Pat. No. 4,737,532. Inaddition, several issued U.S. Patents disclose composite materialscomprising polyethylene (high- or low-density, HDPE and LDPE,respectively) in combination with cellulose fibers, such as U.S. Pat.No. 5,082,605, U.S. Pat. No. 5,088,910, U.S. Pat. No. 5,096,046, U.S.Pat. No. 5,474,722, U.S. Pat. No. 5,480,602, and U.S. Pat. No.6,758,996.

Wood plastic composite lumber being derived from soft thermoplastic hasan issues related to scratch, mar and dent resistance. Often, anextrusion that is smooth or embossed is commonly used for decking andwindow applications. Although wood plastic composites are beingevaluated for siding, these are generally limited to smooth or embossedsiding products. These smooth or smooth embossed surfaces also have ahigher gloss due to the plastic loadings. A smooth or smooth embossedsurface for wood composite decking is required in order to avoidexposure of the raw wood particles which will decrease moistureresistance and potentially create mold on the surface. Furthermore dueto the wood inputs, many of these wood plastic lumber composites requiresome form of coating or capstock to protect it from fade and degradationof the lignin containing wood within the composite matrix.

Various methods are commonly used in the production of composite sidingincluding embossing. The embossing process uses a metal roller with awood like texture to press a wood texture image into the composite underheat and pressure conditions. Example U.S. Patents and U.S. PatentApplication related to embossing include U.S. Pat. No. 8,955,281, U.S.Patent Application No. 2005/0053767, U.S. Patent Application No.2005/0127345, U.S. Pat. No. 5,331,602, U.S. Pat. No. 4,141,944, U.S.Pat. No. 5,906,840, U.S. Pat. No. 5,314,325, U.S. Pat. No. 6,823,794,U.S. Pat. No. 6,641,384, U.S. Pat. No. 5,053,176, U.S. Pat. No.5,866,054, U.S. Pat. No. 5,869,176, U.S. Pat. No. 5,387,381, and U.S.Pat. No. 3,936,518.

Most composite panels such as wood composites, wood plastic composites,and cement fiberboard all have the ability to expand and contract withchanges in moisture content or heat changes related to direct sunlightor extreme temperature changes. In many cases such as wood compositesand cement fiberboard composite siding panels, siding panels are cut andbutted together in which the edges of the composite siding are sealedand the seams are caulked for protection. In many cases directly beneaththe seam joints, a flashing tape or piece is nailed so that if waterdoes follow or penetrate a siding but joint, the house sheathing doesnot become wet or mold. Example U.S. Patents related joint and flashingsystems include U.S. Pat. No. 6,564,521, U.S. Pat. No. 5,344,700, U.S.Pat. No. 5,373,678, U.S. Pat. No. 5,950,389, U.S. Pat. No. 5,628,158,U.S. Pat. No. 5,842,314, U.S. Pat. No. 5,349,796, U.S. Pat. No.5,519,971, and U.S. Pat. No. 5,373,678.

SUMMARY

This Summary is provided to introduce a selection of concepts that arefurther described herein in the Detailed Description. This Summary isnot intended to identify key or central features from the claimedsubject matter, nor is it intended to be used in limiting the scope ofthe claimed subject matter.

Certain examples of wall panel systems for mounting to a wall include apanel having opposite side ends, an upper end, a lower end opposite theupper end, a front surface, a rear surface opposite the front surface, afirst rib on the rear surface that extends outwardly from the rearsurface, and a second rib on the rear surface that extend outwardly fromthe rear surface. The first rib has a rib surface for contacting thewall and a rib depth defined as a distance between the rear surface andthe rib surface of the first rib, and the second rib has a rib surfacefor contracting the wall and a rib depth defined as a distance betweenthe rear surface and the rib surface of the second rib. The rib depth ofthe second rib is greater than the rib depth of the first rib. The panelcan further comprise a third rib on the rear surface that extendsoutwardly from the rear surface. The third rib has a rib surface forcontracting the wall and a rib depth defined as a distance between therear surface and the rib surface of the third rib. The rib depth of thethird rib is greater than the rib depth of the second rib, and the ribsurface of the third rib and the rib surface of the second rib arecoplanar. The panel can include a first portion having a front surfaceand an inner surface and a second portion having a rear surface and aninner surface that abuts the inner surface of the first portion. Thefirst portion includes a plurality of scores each including a firstscore depth defined as a distance between the front surface and theinner surface, and the second portion is removably coupled to the firstportion such that scores can be included in the second portion to mimicthe scores included in the first portion.

Certain examples of wall panel systems for mounting to a wall include afirst panel and a second panel each having opposite side ends, an upperend, a lower end opposite the upper end, and opposite front and rearsurfaces. The first and second panels are arranged in parallelorientation such that the opposite end of the first panel abuts oneopposite end of the second panel to define a seam. Each of the panelsincludes a plurality of aligned holes that are parallel to the uppersurface and positioned closer to the upper surface than the lowersurface. A joint clip for coupling the panels is included such that thepanels remain coupled to each other as the panels thermally deform. Thejoint clip has a first pin that is received in one of the plurality ofholes of the first panel and a second pin that is received in one of theplurality of holes of the second panel.

Various other features, objects and advantages of the present disclosurewill be made apparent from the following description taken together withthe drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of wall panel systems, components thereof, and methods ofassembling and refinishing wall panels systems are described withreference to the following drawing FIGURES. The same numbers are usedthroughout the FIGURES to reference like features and components.

FIG. 1 is a side view of an example wall panel system constructed of anextruded composite material panels.

FIG. 2 is a cross section of an individual panel used in the wall panelsystem of FIG. 1.

FIG. 3A is a front view of an example panel.

FIG. 3B is a front view of two example panels of FIG. 3A abutting eachother.

FIG. 4 is an enlarged view of line 4-4 shown on FIG. 2 depicting scoresand material projections in a first undamaged position.

FIG. 5 is an enlarged view of line 4-4 shown in FIG. 2 depicting thematerial projections in a second damaged position.

FIG. 6 is an enlarged view of line 4-4 shown in FIG. 2 depictingportions of the material projections removed.

FIG. 7 is an enlarged view of line 4-4 shown in FIG. 2 depicting thescores and material projections with portions of the materialprojections removed with reference in phantom to the scores and thematerial projections in the first undamaged position shown in FIG. 4.

FIG. 8 is an enlarged view of line 8-8 shown in FIG. 2 depicting a firstportion and a second portion of an example panel.

FIG. 9 is a side view of an example wall panel system constructed ofextruded composite material panels.

FIG. 10 is a cross section of an individual panel used in the system ofFIG. 9.

FIG. 11 is a side view of an example wall panel system constructed ofextruded composite material panels.

FIG. 12 is a cross section of an individual panel used in the system ofFIG. 11.

FIG. 13 is a side view of an example wall panel system constructed ofextruded composite material panels.

FIG. 14 is a cross section of an individual panel used in the system ofFIG. 13.

FIG. 15 is a side view of a starter strip.

FIG. 16 is a top view of a joint clip.

FIG. 17 is a side view of the joint clip of FIG. 16.

FIG. 18 is a front view of an example flashing.

FIG. 19 is a side view of an example flashing.

FIG. 20 is a front view of the example flashing of FIG. 19.

DETAILED DESCRIPTION OF THE DRAWINGS

In the present disclosure, certain terms are used for brevity, clearnessand understanding. No unnecessary limitations are to be impliedtherefrom beyond the requirement of the prior art because such terms areused for descriptive purposes only and are intended to be broadlyconstrued. The different apparatuses, systems and methods describedherein may be used alone or in combination with other apparatuses,systems and methods. Various equivalents, alternatives and modificationsare possible within the scope of the appended claims.

The present disclosure is described herein using several definitions, asset forth below and throughout the application. Unless otherwisespecified or indicated by context, the terms “a”, “an”, and “the” mean“one or more.” For example, “a compound” should be interpreted to mean“one or more compounds.”

As used herein, “about,” “approximately,” “substantially,” and“significantly” will be understood by persons of ordinary skill in theart and will vary to some extent on the context in which they are used.If there are uses of these terms which are not clear to persons ofordinary skill in the art given the context in which they are used,“about” and “approximately” will mean plus or minus <10% of theparticular term and “substantially” and “significantly” will mean plusor minus >10% of the particular term.

As used herein, the terms “include” and “including” have the samemeaning as the terms “comprise” and “comprising” in that these latterterms are “open” transitional terms that do not limit claims only to therecited elements succeeding these transitional terms. The term“consisting of,” while encompassed by the term “comprising,” should beinterpreted as a “closed” transitional term that limits claims only tothe recited elements succeeding this transitional term. The term“consisting essentially of,” while encompassed by the term “comprising,”should be interpreted as a “partially closed” transitional term whichpermits additional elements succeeding this transitional term, but onlyif those additional elements do not materially affect the basic andnovel characteristics of the claim.

Wall panel systems can vary and can include siding panel systems (orsiding panels) for cladding exterior walls of buildings, interior accentwalls for cladding interior walls for aesthetic and non-aestheticpurposes, screen walls for concealing air handling equipment, and/or thelike. In the instance of siding panel systems, various siding panelsystems are commercially available and can include lap siding (i.e. longpanels designed to overlap with each other), board and batten siding(i.e. a vertical pattern created using boards and battens of variouswidths), sheet or panel siding (i.e. sheets of material laminated ontofoam), shaking siding (i.e. constructed from pieces of wood that aresplit), solid surface resilient composite shakes (i.e. extruded boardsor planks that are deep wire brushed and then cut into variousgeometries and shapes for shake appearance), imitation log siding (i.e.a solid surface resilient composite siding plank that has been deep wirebrushed processed can be either extruded or post heat formed into asemicircle or similar rounded shape with a nailing strip on top toemulate a natural log siding), and the like.

Through research and experimentation the present inventors havedeveloped the concepts in the present disclosure, which include wallpanel components, wall panel systems, and methods for assembling andrefinishing wall panel systems. The present inventors have recognizedthat extruded composite wall panel systems offer significant benefitsover existing wall panel systems. Furthermore, the inventors havediscovered wall panel systems that can be easily repaired or refinishedcan increase the lifespan of the wall panel systems. Various components,systems, and methods for wall panel systems will become apparent fromthe following non-limiting descriptions and drawings herein.

Referring first to FIG. 1, the wall panel system 8 includes a pluralityof extruded composite building panels 10 for mounting to a wall 4. Thepanels 10 are formed by an extrusion process similar to the processdescribed in the U.S. Pat. No. 6,758,996, which is incorporated byreference above. The panels 10 comprise a composite material including apapermaking sludge and a polymer composition having a synthetic polymerresin, which is described in U.S. Pat. No. 6,758,996. The compositematerial further comprises an additive including a colorant such thatthe cross-section of the panel 10 has a homogeneous color. The panel 10is configured to absorb impacts with out breaking or fracturing.

The additive further comprises a blowing or foaming agent forfacilitating bonding or fusing of the cellulose and the syntheticpolymer resin. The amount of blowing agent included is between 0.5-5.0percent of the amount of the thermoplastic material. As described inU.S. Pat. No. 6,758,996, the papermaking sludge comprises chemicallyprocessed cellulose materials. The present inventors have discoveredthat the chemically processed cellulose materials has an acidic pH thatassists in bonding the cellulose material composition to the syntheticpolymer resin (e.g. polyethylene (PE), polypropylene (PP), polyvinylchloride (PVC), polystyrene (PS)) and that other thermoplastics that donot typically bond with non-chemically processed cellulose materials.The present inventors have also discovered that the composite materialincluding the additive with the blowing agent further facilitates orassists (or otherwise increases) the bonding of the cellulose materialcomposition to the synthetic polymer resin of the composite material.The blowing agent reduces the profile density of the extruded compositematerial by 20-25 percent while maintaining the characteristics of thecomposite material and ability to score or heavy wire brush the surfaceas discussed herein and in U.S. Pat. No. 6,758,996. The presentinventors have also discovered that the composite material including theadditive with the blowing agent absorbs less water and/or moisture thanconventional composite materials that comprise wood particles.

The blowing agent can be any composition of chemicals which release agas during thermal decomposition. The blowing agent utilized can beselected from chemicals containing decomposable groups such as azo,N-niroso, carboxylate, carbonate, hetero-cyclic nitrogen-containing andsulfonyl hydrazide groups, that generally, liberate gas when heated bymeans of a chemical reaction or upon decomposition. Examples of blowingagents include azodicarbonamide, bicarbonates, dinitrosopentamethylenetetramethylene tetramine, p,p′-oxy-bis (ben-zenesulfonyl)-hydrazide,benzene-1,3-disulfonyl hydrazide, aso-bis-(isobutyronitrile), biuret,urea, and any like composition.

Other natural blowing agents can be added to impart nitrogen or carbondioxide foaming. The natural blowing agents can comprise variousproteins such as chemically processed corn proteins from ethanolproduction and other proteinaceous materials that release carbon dioxideand/or nitrogen when placed under heat and or kinetic energy inputs. Therelease of carbon dioxide and/or nitrogen initiates from each proteinparticle at a slower rate, thus providing a microcellular nucleatedfoaming process.

Foaming agents can be used in place of the blowing agent as describedabove. Foaming agents can be selected from endothermic and exothermicvarieties, such as dinitrosopentamethylene tetramine, p-toluene solfonylsemicarbazide, 5-phenyltetrazole, calcium oxalate,trihydrazino-s-triazine, 5-phenyl-3,6-dihydro-1,3,4-oxandiazin-2-one,3,6-dihydro 5,6-diphenyl-1,3,4-oxadiazin-2-one, azodicarbonamide, sodiumbicarbonate, and mixtures thereof.

The panels 10 are extruded such that the material composition of thepanel 10 is homogeneous, and the panel 10 has a uniform cross-section(see FIG. 2) and is rectangular (see FIG. 3A). Referring now to FIGS.4-7, each panel 10 includes an integral first portion 11 and an integralsecond portion 21. The first and second portions 11, 21 are extrudedtogether such that the composition of the first and second portions 11,21 are uniform and coupled to each other. The first portion 11 has afront surface 12 and an inner surface 15 opposite the front surface 12.The second portion 21 has a rear surface 22 and an inner surface 23opposite the rear surface 22 (see also FIG. 8). The rear surface 22 ispositioned closer to the wall 4 than the front surface 12 (see FIG. 1).The inner surface 15 of the first portion 11 is abuts the inner surface23 of the second portion 21.

The first portion 11 includes a plurality of grooves or scores 16configured to form a pattern, texture, or visual appearance on the firstportion 11 and each score 16 extends inwardly from the front surface 12.Each score 16 has a first score depth 17 defined as a distance betweenthe front surface 12 and the inner surface 15 of the first portion 11(see also FIG. 8). The scores 16 may be applied to the first portion 11by a wire brush that rotates over the front surface 12 of the firstportion 11 after the panel 10 is extruded. The scores 16 are scored oretched into the first portion 11 through the front surface 12 of thefirst portion 11 such that material projections 18 are defined in andincluded with the first portion 11. The material projections 18 aredisposed between adjacent scores 16. In other examples, the scores 16are applied during the extrusion process. The number of scores 16 in thefirst portion 11 can vary. The orientation of the scores 16 can varysuch as linear, crosshatched, random, and/or the like. In some examples,the scores 16 create a wood texture pattern that mimics the appearanceof real wood. In other examples, the scores 16 create a dull visualappearance in contrast to a glossy visual appearance.

The scores 16 included with the first portion 11 are configured to berepaired and/or reconstructed. FIG. 4 depicts the scores 16 and thematerial projections 18 undamaged. However, the panel 10 can be damagedby impact (e.g. hail, rail, tree branches, baseballs), wear and tearand/or environmental impact (e.g. sunlight, moisture) that can changethe visual appearance of the panel 10 and/or damage the scores 16 and/ormaterial projections 18 included with the first portion 11. FIG. 5depicts damaged material projections 18 where the material projectionsextend or bend into adjacent scores 16. Specifically, materialprojections 18 of the first portion 11 may be bent from a firstundamaged position (the dashed lines on FIG. 5 represent the firstundamaged position of the material projections 18) to a second damagedposition (see the solid lines on FIG. 5 that represents an example ofthe material projections 18 moving into the adjacent scores 16 due to anexternal damaging force) such that the material projections 18 move intothe scores 16 disposed adjacent to the material projections 18. Themovement of the material projections 18 into the scores 16 changes thevisual appearance of the panel 10. In one example, the panel 10 isrepaired or refinished by bending the material projection back to thefirst undamaged position (see FIG. 4). The material projections 18 arebent by a tool such as a wire brush. In another example, the panel 10 isrepaired or refinished by removing portions of the material projections18 that moved into the adjacent scores 16 (the dashed lines of FIG. 6represent the portion of the material projections 18 that are removedand the solid lines represent the remaining material projections 18; thedashed lines of FIG. 7 represent the first undamaged position of thematerial projections 18 and the solid lines of FIG. 7 represent theportions of the material projections 18 remaining). The portions of thematerial projections 18 can be removed by a tool, such as a razor or awire brush.

In another alternative shown in FIG. 8, the panel 10 is repaired orrefinished by removing the first portion 11 and adding scores to thesecond portion 21 as described above with reference to the scores 16 ofthe first portion 11. The first portion 11 is removably coupled to thesecond portion 21 such that the first portion can be removed, orotherwise modified, to expose the second portion 21. The first portion11 can be removed or modified by a tool such as a wire brush, razor, orthe like. Removal of the first portion 11 exposes the second portion 21.The second portion 21 receives scores 26 and defines materialprojections 28 similar to the scores 16 and material projections 18described with reference to the first portion 11 such that the visualappearance of the panel 10 without the first portion 11 is identical tothe visual appearance of the panel 10 with the first portion 11 (seeFIG. 8). The scores 26 of the second portion 21 are identical to thescores 16 of the first portion 11 such that the pattern, texture, orvisual appearance of the inner surface 23 of the second portion 21mimics or is identical to the pattern, texture, or visual appearance ofthe front surface 12 of the first portion 11. The scores 26 included andreceived by the second portion 21 have a second score depth 27 definedbetween the inner surface 23 of the second portion 21 and a score depthplane 29 defined between the rear surface 22 and inner surface 23 of thesecond portion 21. The second score depth 27 is equivalent to the firstscore depth 17.

Non-limiting examples of wall panel systems 8 are depicted in FIGS. 1-2,9-10, 11-12, and 13-14. The example wall panel systems 8 depicted caninclude any of the features or combination of features described herein.Each wall panel system 8 includes a plurality of panels 10, and thepanels 10 may have the scoring characteristics described above.

Referring to FIGS. 3A-3B, the each panel 10 includes opposite side ends30 that abut the opposite side ends 30 of parallel panels such that theopposite side ends 30 of the parallel panels 10 define a seam 32 betweeneach panel 10. The panels 10 are arranged in a parallel abuttingend-to-end orientation such that the panels 10 span a length of the wall4. The panels 10 are stacked immediately above lower panels such thatthe panels 10 span a vertical height of the wall 4 (see FIG. 1). Eachpanel 10 includes an upper end 36 having a tongue 38 configured to matewith a groove 62 (to be described herein) of the panel 10 immediatelyabove (see also FIG. 1) and a lower end 44 having a lip 46 configured tooverlap the upper end 36 of the panel 10 immediately below. Asdemonstrated in FIGS. 1, 2, 3A and 3B, the lip 46 is configured tooverlap holes 40 (described herein below) of the panel 10 immediatelybelow. The lip 46 includes a sloped surface 47 defined by an angle Afrom a vertical direction V.

The panels 10 include a plurality of aligned holes 40 for securing thepanels 10 to the wall 4 with a fastener 41, such as nail or screw. (seeFIGS. 1 and 3A-3B). The holes 40 are aligned on the panel 10 and extendbetween the front and rear surfaces 12, 22 of the panel 10. The holes 40are parallel to the upper end 36 and positioned closer to the upper end36 than the lower end 44 (see FIG. 3A-3B). The shape of the holes 40 canvary. In one example, at least one hole 40 is oblong and at least onehole 40 is circular. The holes 40 are equidistant from each other and/oruniformly spaced on the panel 10. The number, spacing, and shape of theholes 40 depicted in FIGS. 3A-3B are merely exemplary and the holes 40may vary from that which is shown.

Referring to FIG. 2, the panel 10 includes a first rib 51, a second rib54, and a third rib 57 on the rear surface 22. The ribs 51, 54, 57extend outwardly from the rear surface 22. In one non-limiting example,the ribs 51, 54, 57 span continuously along the rear surface 22 betweenthe opposite side ends 30. Each rib 51, 54, 57 has a rib surface 52, 55,58, respectively, for contacting the wall 4 (see FIG. 1) and a rib depth53, 56, 59, respectively, defined as a distance between the rear surface22 and the rib surface 52, 55, 58, respectively (i.e. the first rib 51has a rib surface 52 and a rib depth 53, the second rib 54 has a ribsurface 55 and a rib depth 56, and the third rib 57 has a rib surface 58and a rib depth 59). The rib depth 59 of the third rib 57 is greaterthan the rib depth 56 of the second rib 54, and the rib depth 56 of thesecond rib 54 is greater than the rib depth 53 of the first rib 51 (seeFIG. 2). The rib surfaces 52, 55, 58 are coplanar (see plane P depictedon FIG. 2), and rib surfaces 52, 55, 58, lie flush with the wall 4 whenthe panel 10 is mounted to the wall 4 (see FIG. 1). At least one ribincludes a groove 62 configured to receive the tongue 38 of the upperend 36 (which is described above) of the panel 10 immediately below whenthe panels 10 are stacked (see FIG. 1). In certain examples, the thirdrib 57 includes the groove 62 (see FIGS. 2, 10, 12, 14). At least onerib includes a starter groove 64 (see FIG. 12) configured to receive astarter tongue 69 of a starter strip 68 (described herein below) (seeFIG. 15).

Referring to FIG. 2, the panel 10 includes a recess 13 configured toreceive the fastener 33 such that fastener 33 is flush with the frontsurface 12 of the panel 10. The recess 13 is aligned with the holes 40,and the recess 13 extends along a length of the panel 10. The frontsurface 12 of the panel 10 includes a sloped surface 14 defined by angleA. The sloped surface 14 of the front surface 12 is parallel to thesloped surface 47 of the lip 46 of the lower end 44 such that the slopedsurface 47 of the lip 46 of the panel 10 immediately above lies or isflush with the sloped surface 14 of the front surface 12 of the panel 10immediately below (see FIG. 1). The rear surface 22 includes a slopedsurface 24 that is parallel to the sloped surface 14 of the frontsurface 12. In another example, the front and rear surfaces 12, 22 arevertical and parallel to each other (see FIG. 14).

Referring to FIG. 15, the wall panel system 6 includes the starter strip68 for mounting to the wall 4 and configured to contact with the panel10 immediately above (see FIG. 12). The starter strip 68 includes thestarter tongue 69 that is configured to be received in the startergroove 64 of a second rib 54 (see FIG. 12). The starter strip 68includes a fastener 70 for mounting the starter strip 68 to the wall 4(see FIG. 11).

Referring to FIGS. 16-17, the wall panel system 8 includes a pluralityof joint clips 80 for coupling the panels 10 in parallel end-to-endorientation (described above). The joint clip 80 allows the panels 10 tothermally expand and contract relative to each other. The joint chip 80maintains a mechanical connection between the panels 10. The joint clip80 includes a base 82, a first pin 84 for engaging with the hole 40 ofthe panel 10, and a second pin 86 for engaging with the hole 40 of theparallel abutting panel 10 such that the joint clip 80 overlaps the seam32 between the panels 10 (see FIG. 3B). The first and second pins 84, 86are on the base 82 and project outwardly away from the base 82. Thefirst and second pins 84, 86 are dimensioned to be received in the holes40 of the panels 10. The number of pins on the base 82 can vary. Thefirst and second pins 84, 86 are received by the holes 40 such that thebase 82 is adjacent to the rear surface 22. The first and second pins84, 86 comprise a plurality of barbs 88 for engaging with the holes 40such that the joint clip 80 securely attaches to the panels 10. Thebarbs 88 project radially from the pins 84, 86 and elastically deform aspins 84, 86 are inserted into the holes 40 of the panels 10. The barbs88 resist removal of the joint clip 80 from the holes 40.

Referring to FIGS. 18-20, the wall panel system 8 includes a pluralityof flashings 90 for covering the seams 32 between abutting parallelpanels 10. The flashing 90 is sandwiched between the joint clip 80 andthe rear surfaces 22 of abutting panels 10 such that the flashing 90overlaps the seam 32. The flashing 90 prevents rain, ice, and/or otherelements from reaching the wall 4 (see FIG. 1). The flashing 90 has aheight that corresponds to the distance between the upper end 36 and thelower end 44 of the panel 10. The height and number of holes 40 of theflashing 90 can vary.

In one example (depicted by FIG. 18), each flashing 90 includes an upperend 92, a first flashing hole 96, and a second flashing hole 98 which isaligned with the first flashing hole 96. The first and second flashingholes 96, 98 are parallel and adjacent to the upper end 92 of theflashing 90. The flashing 90 is a flat metal plate. In operation, thefirst flashing hole 96 is aligned with the hole 40 of the panel 10 andthe second flashing hole 98 is aligned with the hole 40 of the abuttingpanel 10 (see also FIG. 3B). The first flashing hole 96 receives thefirst pin 84 of the joint clip 80 and the second flashing hole 98receives the second pin 86 of the joint clip 80 such that the joint clip80 and flashing 90 overlap the seam 32 and the flashing 90 is adjacentto the rear surfaces 22 of the panels 10. In an alternative example, thefirst and second flashing holes 96, 98 are formed when the first andsecond pins 84, 86 of the joint clip 80 pierce the flashing 90. Inanother example (depicted by FIGS. 19-20), the flashing 90 is a bentmetal plate having a plurality of channels 99 for engaging and/orlocking to the panels 10. The flashing 90 includes a plurality of holes100 which align with holes 40 of the panels 10 (see FIG. 3B).

Certain examples of wall panel systems include solid surface resilientcomposite siding panels further comprising a cellulose, mineral,thermoplastic composite, wherein the extruded composite siding ishomogenous and also includes a color throughout the siding shape.Certain examples of wall panel systems include scores or deep wirebrushed surfaces that impart functional performance and aestheticsurface properties providing both high durability and robustness whilebeing repairable and having a very low gloss with a surface resemblingcross cut lumber.

Certain examples of wall panel systems include high levels of granulatedpaper-making sludge mixed with plastic, and, if desired, cellulosefiber, to form composite materials that exhibit high strength, highmodulus, high impact resistance, and good resistance to decay,non-flammable properties. Certain examples of wall panel systems includecomposite formulation useful as a feedstock in the manufacture ofcomposite end products. The feedstock composite can contain granulatedpaper-making sludge and plastic. The feedstock may also containcellulose fiber (e.g., agricultural by-products in a short-fiber form,such as rice hulls, cotton linters, ground cotton and other plantfibrous materials, fibers from textile manufacturing, pulping and paperconverting operations, recycling of paper and wood products, etc.), and,if desired, additives such as reinforcing agents, lubricants, colorants,compatibilizers, and/or flame retardants. Certain examples of wall panelsystems can utilize paper-making sludge that would otherwise be disposedof as industrial waste. Certain examples of wall panel systems utilize apaper mill waste product. Certain examples of wall panel systems includecellulosic particulate selected from the group consisting of wood fiber,wood flour and combinations thereof. It will be understood by a personskilled in the art that wood pulp can be any known wood pulp material,for example, thermo-mechanical wood pulp, chemical thermo-mechanicalwood pulp and combinations thereof.

Certain examples of wall panel systems include material or particulates.Certain examples of wall panel systems included additives and/orcolorants. Certain examples of wall panel systems include antioxidants,UV stabilizers, foaming agents, dyes, pigments, cross-linking agents,inhibitors, and/or accelerators. Certain examples of wall panel systemsinclude means for compounding and removing moisture. Certain examples ofwall panel systems include using a rotary wire brush on a spinningmandrel to create a random linear surface from a depth from 0.010″ to0.2″. Certain examples of wall panel systems include using a high speedlaser engraving. Certain examples of wall panel systems include scoresor a deep wire brush effect to a depth of 0.010″ to over 0.125″ into thesurface. Certain examples of wall panel systems include resilient andrepairable composite panels, siding, and/or siding panels. Certainexamples of wall panel systems include panels in the shape of a lapsiding, board, plank, panel, board and batten, or other wall or sidingshape with a flat area that represents the outside surface of the panel.Certain examples of wall panel systems include brushing the panel with aheavy wire rotary brush in line with the composite extrusion system orprocess to a depth between 0.005″ to over 0.2″

Certain examples of wall panel systems include resilient, robust,durable and repairable panels that reduce or overcome some or all of thedifficulties inherent in prior known devices. Certain examples of wallpanel systems can create a resilient and repairable composite lap panelthat integrates holes and a joint clip as to allow the panels to expandor contract without creating large gaps at the seams between sidingboards. Certain examples of wall panel systems include joint clips thatholds panels and panel seams together during siding movement and aflashing beneath the panels and/or panel seams to prevent water ormoisture to reach the plywood or OSB shell or walls of a building thatis mounted to the wall panel system instead of the walls of thebuilding. Certain examples of wall panel systems include panels that canexpand and contract in a “floating” process such that the joint clipholds the abutting panels together at the seams so that no gaps betweenthe panels are defined. In certain examples, the flashings align withthe seams for water and air flow protection.

Through research and experimentation, examples of the composite materialof the present disclosure that include the blowing agent or foamingagent have been observed to reduce the profile density of the compositematerial by 20-25 percent when compared to composite material withoutthe blowing agent. The composite material with the blowing agentmaintains the characteristics of the composite material without theblowing agent including the solid surface nature and ability to score orheavy wire brush the surface without increasing the water absorption ofthe composite material. In one example experiment, a sample of thecomposite material with the blowing agent and a sample of a commerciallyavailable wood plastic composite were compared for water resistance.Moisture resistance can increase resistance to expansion, mold, anddegradation of the composite material. The thickness of the samples were0.25 inches, and the sample set included a commercial wood plastic witha smooth surface, a commercial wood plastic with a wire brushed surface,the composite material with blowing agent and a smooth surface, and thecomposite material with blowing agent and a wired brushed surface. Thewired brushed surface samples were scored or brushed to an approximatedepth of 1/16 inches. The samples were placed in water for 24 hours andmeasured for both the weight gain and expansion of the samples. Theweight gain results included: the commercial wood plastic with a smoothsurface +2.2 percent weight gain; the commercial wood plastic with awire brushed surface +2.7 percent weight gain; the composite materialwith blowing agent and a smooth surface +0.62 percent weight gain; andthe composite material with blowing agent and a wired brushed surface+0.62 percent weight gain. The 24 hour immersion weight gain showedsignificant increase in water absorption within the commercial woodplastic due to the water reaching individual particles of wood withinthe composite. The composite material with blowing agent showed lessthan half of the water absorption than the wood plastic composite. Inaddition, the commercial wood plastic gained more moisture weight with abrushed surface, and the weight gain of the composite material withblowing agent did not change with a brushed surface.

The samples were also measured for expansion based on the 24 hour soak.The commercial wood plastic expanded more and had a bumpy texture due tothe expansion of the wood particles, and the composite material withblowing agent remained smooth with little to no expansion.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to make and use the invention. The patentable scope of the inventionis defined by the claims, and may include other examples that occur tothose skilled in the art. Such other examples are intended to be withinthe scope of the claims if they have structural elements that do notdiffer from the literal language of the claims, or if they includeequivalent structural elements with insubstantial differences from theliteral languages of the claims.

What is claimed is:
 1. A wall panel system for mounting to a wall, thewall panel system comprising: a panel comprising: opposite side ends; anupper end; a lower end opposite the upper end; a front surface; a rearsurface opposite the front surface; a first rib on the rear surface thatextends outwardly from the rear surface, the first rib having a ribsurface for contacting the wall and a rib depth defined as a distancebetween the rear surface and the rib surface of the first rib; and asecond rib on the rear surface that extend outwardly from the rearsurface, the second rib having a rib surface for contracting the walland a rib depth defined as a distance between the rear surface and therib surface of the second rib, wherein the rib depth of the second ribis greater than the rib depth of the first rib.
 2. The wall panel systemaccording to claim 1, wherein the rib surface of the first rib and therib surface of the second rib are coplanar.
 3. The wall panel systemaccording to claim 2, wherein the panel is one of plurality of panels,wherein the panels are arranged in a stacked and parallel abuttingend-to-end orientation; the lower end of the panel comprises a lipconfigured to overlap the upper end of one of the plurality of panelsimmediately below.
 4. The wall panel system according to claim 3,wherein the panel comprises a plurality of holes aligned parallel withthe upper end, and wherein the lip of the lower end is configured toover lap the plurality of holes of one of the plurality of panelsimmediately below.
 5. The wall panel system according to claim 4,wherein the lip comprises a sloped surface configured to have flushcontact with the front surface of one of the plurality of panelsimmediately below.
 6. The wall panel system according to claim 5,wherein the front surface comprises a sloped surface that is parallel tothe sloped surface of the lip.
 7. The wall panel system according toclaim 1, wherein panel comprises a papermaking sludge and a polymercomposition having a synthetic polymer resin.
 8. The wall panel systemaccording to claim 7, wherein the panel comprises a blowing agent. 9.The wall panel system according to claim 1, wherein the panel is one ofplurality of panels, and wherein the panels are arranged in a stackedand parallel abutting end-to-end orientation; wherein the panel furthercomprises a third rib on the rear surface that extend outwardly from therear surface, the third rib having a rib surface for contracting thewall and a rib depth defined as a distance between the rear surface andthe rib surface of the third rib, wherein the rib depth of the third ribis greater than the rib depth of the second rib, the rib surface of thethird rib and the rib surface of the second rib are coplanar.
 10. Thewall panel system according to claim 9, wherein the third rib furthercomprises a groove configured to receive the upper end one of theplurality of panels immediately below.
 11. The wall panel systemaccording to claim 1, wherein the panel further comprises: a firstportion having a front surface and an inner surface, the first portionhaving a plurality of scores each including a first score depth definedas a distance between the front surface and the inner surface; a secondportion having a rear surface and an inner surface that abuts the innersurface of the first portion, wherein the second portion is removablycoupled to the first portion such that scores can be included in thesecond portion to mimic the scores included in the first portion. 12.The wall panel system according to claim 11, wherein the first portionand the second portion extrude as a unitary panel; and wherein the firstportion and the second portion comprise a papermaking sludge and apolymer composition having a synthetic polymer resin.
 13. The wall panelsystem according to claim 12, wherein the first and second portionscomprise an additive including a colorant.
 14. The wall panel systemaccording to claim 13, wherein the second portion has a maximum scoredepth plane defined between the rear surface of the second portion andthe inner surface of the second portion; and wherein the second portionis configured to receive a plurality of scores each having a secondscore depth defined as the distance between the inner surface of thesecond portion and the maximum score depth plane.
 15. The wall panelsystem according to claim 14, wherein the second score depth isequivalent to the first score depth.
 16. A wall panel system formounting to a wall, the wall panel system comprising: a first panel anda second panel each having an opposite side ends, an upper end, a lowerend opposite the upper end, and opposite front and rear surfaces,wherein one opposite end of the first panel abuts one opposite end ofthe second panel to define a seam; each of the panels includes aplurality of aligned holes that are parallel to the upper surface andpositioned closer to the upper surface than the lower surface; and ajoint clip for coupling the panels such that the panels remain coupledto each other as the panels thermally deform, the joint clip has a firstpin that is received in one of the plurality of holes of the first paneland a second pin that is received in one of the plurality of holes ofthe second panel.
 17. The wall panel system according to claim 16,wherein each joint clip comprises a base configured to couple with thefirst and second pins, wherein the base overlaps the seam.
 18. The wallpanel system according to claim 17, wherein the first and second pinseach comprise a barb configured to elastically deform and secure thejoint clip to the pair of panels.
 19. The wall panel system according toclaim 16, further comprising: a flashing for covering the seam, eachflashing having an upper end, a lower end, a first flashing hole and asecond flashing hole aligned with the first flashing hole, the first andsecond flashing hole are parallel to the upper end of the flashing andpositioned closer to the upper end of the flashing than the lower end ofthe flashing; wherein the first flashing hole aligns with one of theplurality of holes of the first panel and the second flashing holealigns with one of the plurality of holes of the second panel.
 20. Thewall system according to claim 18, wherein the first and second flashingholes receive the first and second pins of the joint clip.
 21. The wallsystem according to claim 16, wherein the pair of panels comprise acomposite material comprising a papermaking sludge and a polymercomposition comprising a synthetic polymer resin.
 22. The wall panelsystem according to claim 21 wherein the composite material furthercomprises a blowing agent.